While working with Mangostone on their Lapland project, we were commissioned to create four sets of bespoke, ultra-lightweight faux antlers for two sets of animatronic reindeer. Our brief was to produce lifelike yet extremely strong antlers that would not affect the movement of the reindeers’ heads, making weight a critical consideration throughout the process.

To meet the client’s brief, we combined 3D scanning technology with both digital and practical sculpting techniques. This allowed us to manipulate the scan data to precisely match the client’s drawings and design requirements. The final antlers were resin 3D printed using a super-strong material, internally reinforced with carbon fibre, and then meticulously painted and flocked to achieve a highly realistic, lifelike finish.

In addition to the antlers, Gallo Makes also assisted with aspects of the reindeer fabrication, including airbrushing and hair-punching the heads. All other elements of the project were completed by the talented team at Mangostone.